PPAP Level 3: Why Documentation is as Important as the Part itself.

PPAP Level 3: Why Documentation is as Important as the Part Itself

Problem Statement: Compression Set Failure in High-Temperature Seals

Automotive turbocharger seals require stable performance at 200°C and 15 bar pressure. Standard NBR compounds degrade rapidly, losing >40% sealing force after 500 thermal cycles due to polymer chain scission.

Material Science Analysis

FKM outperforms NBR and EPDM in this application due to:

• Fluorine-carbon bonds (68% fluorine content) resist thermal oxidation
• Crosslink density maintains compression set below 20% at 200°C
• ASTM D2000 M6HK 814 A25 B25 E25 F25 classification

Technical Specifications

Parameter	FKM (Recommended)	NBR (Alternative 1)	EPDM (Alternative 2)
Shore A Hardness	75 ±5	70 ±5	65 ±5
Tensile Strength (MPa)	18.5	14.2	9.8
Elongation at Break (%)	220	350	400
Compression Set (%, 22h @ 200°C)	18	65	45
Continuous Use Temp (°C)	-20 to +230	-30 to +120	-50 to +150

Standard Compliance

RubberQ’s IATF 16949 system ensures:

• Full PPAP Level 3 documentation (Process Flow, PFMEA, Control Plans)
• ISO 16232 cleanliness reports for all molded parts
• ASTM D429 adhesion testing for bonded components
• Lot traceability down to raw material batch numbers

For custom material compound development or IATF 16949 documentation, consult RubberQ’s engineering department.